Phosphorus-containing organic-inorganic hybrid nanoparticles for the smoke suppression and flame retardancy of thermoplastic polyurethane

A Comprehensive Review of Reactive Flame Retardants for Polyurethane Materials: Current Development and Future Opportunities in an Environmentally Friendly Direction

Polyurethanes are among the most significant types of polymers in development; these materials are used to produce construction products intended for work in various conditions. Nowadays, it is important to develop methods for fire load reduction by using new kinds of additives or monomers containing elements responsible for materials' fire resistance. Currently, additive antipyrines or reactive flame retardants can be used during polyurethane material processing. The use of additives usually leads to the migration or volatilization of the additive to the surface of the material, which causes the loss of the resistance and aesthetic values of the product. Reactive flame retardants form compounds containing special functional groups that can be chemically bonded with monomers during polymerization, which can prevent volatilization or migration to the surface of the material. In this study, reactive flame retardants are compared. Their impacts on polyurethane flame retardancy, combustion mechanism, and environment are described.

Recent remediation strategies for flame retardancy via nanoparticles

This review article delves into the application of nanoparticles (NPs) in fire prevention, aiming to elucidate their specific contribution within the broader context of various fire prevention methods. While acknowledging established approaches such as fire safety principles, fire suppression systems, fire alarm systems, and the use of fire-retardant chemicals and safety equipment, this review focuses on the distinctive properties of NPs. The findings underscore the remarkable potential of NPs in controlling and mitigating fire propagation within both architectural structures and vehicles. Specifically, the primary emphasis lies in the impact of NPs on reducing oxygen levels, as assessed through the limiting oxygen index , a subject explored by various researchers. Furthermore, this review delves into the examination of combustion reduction rates facilitated by NPs, utilizing assessments of ignition time, heat release rate (HRR), and flammability tests (UL-94) on plastic materials. Beyond these aspects, the review evaluates the multifaceted role of NPs in achieving weight reduction and establishing fire-retardant properties. Additionally, it discusses the reduction of smoke, a significant contributor to environmental pollution and health risks. Among the nanoparticles investigated in this study, SiO2, MgAl, and nano hydrotalcite have demonstrated the best results in weight reduction, smoke reduction, and HRR, respectively. Meanwhile, Al2O3 has been identified as one of the least effective treated nanoparticles. Collectively, these findings significantly contribute to improving safety measures and reducing fire risks across a range of industries.

Strategy for Constructing Phosphorus-Based Flame-Retarded Polyurethane Elastomers for Advanced Performance in Long-Term

Polyurethane elastomer (PUE), which is widely used in coatings for construction, transportation, electronics, aerospace, and other fields, has excellent physical properties. However, polyurethane elastomers are flammable, which limits their daily use, so the flame retardancy of polyurethane elastomers is very important. Reactive flame retardants have the advantages of little influence on the physical properties of polymers and low tendency to migrate out. Due to the remarkable needs of non-halogenated flame retardants, phosphorus flame retardant has gradually stood out as the main alternative. In this review, we focus on the fire safety of PUE and provide a detailed overview of the current molecular design and mechanisms of reactive phosphorus-containing, as well as P-N synergistic, flame retardants in PUE. From the structural characteristics, several basic aspects of PUE are overviewed, including thermal performance, combustion performance, and mechanical properties. In addition, the perspectives on the future advancement of phosphorus-containing flame-retarded polyurethane elastomers (PUE) are also discussed. Based on the past research, this study provides prospects for the application of flame-retarded PUE in the fields of self-healing materials, bio-based materials, wearable electronic devices, and solid-state electrolytes.

Synergetic Effect of α-ZrP Nanosheets and Nitrogen-Based Flame Retardants on Thermoplastic Polyurethane

A supramolecular self-assembly method was used to prepare melamine cyanurate/α-ZrP nanosheets (MCA@α-ZrP) as a novel hybrid flame retardant for thermoplastic polyurethane (TPU). Microstructure characterization showed a uniform dispersion with strong interfacial strength of the MCA@α-ZrP hybrid within the TPU matrix, leading to simultaneous enhancements in both mechanical and fire-safety properties. The TPU/MCA@α-ZrP nanocomposite exhibited 43.1 and 47.0% increments in tensile strength and fracture energy, respectively. Thanks to the platelike structure of α-ZrP coupled with the dilution effect of MCA (releasing nonflammable gases), the hybrid MCA@α-ZrP reduced the peak heat release rate of TPU by 49.7% in comparison with 15.8 and 35.4% for TPU/MCA and TPU/ α-ZrP composites, respectively. The fire performance index of TPU is significantly promoted by 90% upon adding the MCA@α-ZrP hybrid. Additionally, LOI and UL-94 tests showed high flame-retarding characteristics for the MCA@α-ZrP hybrid. For example, LOI increased from 20.0% for neat TPU to 25.5% for the MCA@α-ZrP hybrid system, and it was rated V-1 from the UL-94 test. Furthermore, the smoke production and pyrolysis products were significantly suppressed by adding the MCA@α-ZrP hybrid into TPU. Interfacial hydrogen bonding, the dilution effect of MCA, forming a "labyrinth" layer, and catalytic action of α-ZrP nanosheets synergistically improved both the mechanical performance and flame retardancy of TPU nanocomposites. This work provides a new example of integrating traditional flame retardants with functional nanosheets to develop polymeric nanocomposites with high mechanical and fire-safety properties.

Design of PEI and Amine Modified Metakaolin-Brushite Hybrid Polymeric Composite Materials for CO2 Capturing

In this paper, the properties of organic-inorganic hybrid polymer materials, which were synthesized from an aluminosilicate inorganic matrix with the addition of brushite and aminosilane grafted on one side and PEI covalently bonded composites on the other side, were examined. The synthesized organic-inorganic hybrid polymers were examined in terms of a structural, morphological, thermo-gravimetric, and adsorption-desorption analysis and also as potential CO2 capturers. The structural and phase properties as well as the percentage contents of the crystalline and amorphous phase were determined by the X-ray diffraction method. The higher content of the amorphous phase in the structure of hybrid polymers was proven in metakaolin and metakaolin-brushite hybrid samples with the addition of amino silane and with 1,000,000 PEI in a structure. The DRIFT method showed the main band changes with the addition of an organic phase and inorganic matrix. Microstructural studies with the EDS analysis showed a uniform distribution of organic and inorganic phases in the hybrid geopolymers. The thermo-gravimetric analysis showed that organic compounds are successfully bonded to inorganic polymer matrix, while adsorption-desorption analysis confirmed that the organic phase completely covered the surface of the inorganic matrix. The CO2 adsorption experiments showed that the amine-modified composites have the higher capture capacity, which is 0.685 mmol·g−1 for the GM10 sample and 0.581 mmol·g−1 for the BGM10 sample, with 1,000,000 PEI in the structure.

Nanohybrid of Co3O4 Nanoparticles and Polyphosphazene-Decorated Ultra-Thin Boron Nitride Nanosheets for Simultaneous Enhancement in Fire Safety and Smoke Suppression of Thermoplastic Polyurethane

Thermoplastic polyurethane (TPU) is widely used in daily life due to its characteristics of light weight, high impact strength, and compression resistance. However, TPU products are extremely flammable and will generate toxic fumes under fire attack, threatening human life and safety. In this article, a nanohybrid flame retardant was designed for the fire safety of TPU. Herein, Co₃O₄ was anchored on the surface of exfoliated ultra-thin boron nitride nanosheets (BNNO@Co₃O₄) via coprecipitation and subsequent calcination. Then, a polyphosphazene (PPZ) layer was coated onto BNNO@Co₃O₄ by high temperature polymerization to generate a nanohybrid flame retardant named BNNO@Co₃O₄@PPZ. The cone calorimeter results exhibited that the heat release and smoke production during TPU combustion were remarkably restrained after the incorporation of the nanohybrid flame retardant. Compared with pure TPU, the peak heat release rate (PHRR) decreased by 44.1%, the peak smoke production rate (PSPR) decreased by 51.2%, and the peak CO production rate (PCOPR) decreased by 72.5%. Based on the analysis of carbon residues after combustion, the significant improvement in fire resistance of TPU by BNNO@Co3O4@PPZ was attributed to the combination of quenching effect, catalytic carbonization effect, and barrier effect. In addition, the intrinsic mechanical properties of TPU were well maintained due to the existence of the PPZ organic layer.

A Series of Novel Flame Retardants Produced with Nanosilica, Melamine, and Aluminum Diethylphosphinate to Improve the Flame Retardancy of Phenolic Resin

To facilitate the flame retardancy of phenolic resin (PF), a series of novel flame retardants with nano-SiO₂, melamine, and aluminum diethylphosphinate (ADP) were freshly prepared and tested. A thermogravimetric analysis, cone calorimeter, and scanning electron microscopy were employed to determine the thermal decomposition, flame retardancy, combustion properties, and structure of the carbon residue layer of PF. The pyrolysis kinetic parameters of modified PF were then computed, and the pyrolysis process was appraised. The results indicated that when 1.5 wt % of nano-SiO₂, 3 wt % of melamine, and 15 wt % of ADP were added to PF, the limiting oxygen index value reached 39.6%, and UL-94 passed the V-0 level. A substantial synergistic effect was also observed. The thermogravimetric analysis revealed that the char residue at 800 °C reached 59.93 wt %. Furthermore, in the cone calorimeter test, the total thermal release and thermal release rate decreased to 30.7 MJ/m² and 105.7 kW/m², respectively.

Fabrication of thermoplastic polyurethane with functionalized MXene towards high mechanical strength, flame-retardant, and smoke suppression properties

Recently, two-dimensional MXene demonstrated promising advantages to improve the flame-retardant performance of composites; however, its compatibility with polymer matrix is a great concern. In this study, MXene was first functionalized with phosphorylated chitosan (PCS) to obtain the PCS-MXene nanohybrid. The resulting nanohybrid was introduced into the thermoplastic polyurethane (TPU) matrix via solution mixing followed by the hot-pressing method, affording TPU/PCS-MXene nanocomposite. The resulting nanohybrid exhibited superior compatibility with the TPU matrix, enhancing mechanical performance of the TPU/PCS-MXene nanocomposite compared to the pristine TPU and TPU/MXene nanocomposite. Besides, the flame-retardant performance of TPU/PCS-MXene nanocomposite was greatly enhanced, while the smoke emission was effectively suppressed. As only 3 wt% PCS-MXene was introduced, peak heat release rate, total heat release, and total smoke production of the composite decreased by 66.7%, 21.0%, and 27.7%, respectively, compared to the pristine TPU. Systematical characterization was then carried out to investigate the enhancement mechanism of PCS-MXene, highlighting the crucial role of PCS combined with the catalytic effect of MXene. In brief, the compatibility issues of MXene were effectively addressed, and its flame-retardancy enhanced greatly via the PCS modification, the bio-based characteristic of which, in turn greatly benefits the further development of MXene-polymer composite.

Halloysite Nanotubes and Silane-Treated Alumina Trihydrate Hybrid Flame Retardant System for High-Performance Cable Insulation

The effect of the presence of halloysite nanotubes (HNTs) and silane-treated alumina trihydrate (ATH-sil) nanofillers on the mechanical, thermal, and flame retardancy properties of ethylene-vinyl acetate (EVA) copolymer/low-density polyethylene (LDPE) blends was investigated. Different weight percentages of HNT and ATH-sil nanoparticles, as well as the hybrid system of those nanofillers, were melt mixed with the polymer blend (reference sample) using a twin-screw extruder. The morphology of the nanoparticles and polymer compositions was studied using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The mechanical properties, hardness, water absorption, and melt flow index (MFI) of the compositions were assessed. The tensile strength increases as a function of the amount of HNT nanofiller; however, the elongation at break decreases. In the case of the hybrid system of nanofillers, the compositions showed superior mechanical properties. The thermal properties of the reference sample and those of the corresponding sample with nanofiller blends were studied using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Two peaks were observed in the melting and crystallization temperatures. This shows that the EVA/LDPE is an immiscible polymer blend. The thermal stability of the blends was improved by the presence of HNTs and ATH-sil nanoparticles. Thermal degradation temperatures were shifted to higher values by the presence of hybrid nanofillers. Finally, the flammability of the compositions was assessed. Flammability as reflected by the limiting oxygen index (OI) was increased by the presence of HNT and ATH-sil nanofiller and a hybrid system of the nanoparticles.

In situ phthalocyanine synthesis chemistry in flames towards molecular fireproof engineering

The boundaries between phthalocyanine synthesis and combustion chemistry were broken through to achieve molecular fireproofing via in situ phthalocyanine (Pcs) synthesis during combustion. Furthermore in situ Pcs chemistry achieves a flame-retarding organic thermoplastic polymer, showing state-of-the-art fire-safety performance and an ultra-low fire hazard.